Steam Turbines
Steam Turbines
• A steam turbine consists of a
stationary set of blades,
often called nozzles and a
moving set of blades called
buckets, or rotor blades. In a
steam turbine, hot steam at
a pressure above atmosphere
is produced by a boiler, then,
expanded in the nozzle
where the heat energy is
converted to kinetic energy.
• This kinetic energy is then converted into mechanical energy
in the turbine. If the nozzles are fixed and the jets directed at
the movable blades, the impulse from the force of the jets
pushes the blades.
• If the nozzles are free to move, reaction of the jets pushes
against the nozzles forcing them to move in the opposite
direction.
• The stationary and rotating blade components act together to
provide torque to the rotor assembly, which is transmitted
through the shaft to the load (FIGURE 10. illustrates the
typical arrangement of impulse and reaction turbine blade
designs).
• Steam turbines are built in a number of different
configurations to suit the needs of industrial process,
compression, or power plant electrical generation
installations.
• They may be of double (compound), or single cylinder
design. Turbines with single cylinder design are either a
condensing or a back pressure (non-condensing)
machine.
Steam Turbine Lubrication
• The primary lubricated components of steam turbines
are the journal and thrust bearings and depending upon
the design and application of the turbine, a hydraulic
governor control system, seals, accessory gear drive,
flexible coupling and turning gear may also require
lubrication.
• A main oil pump is usually driven by an auxiliary gear
on the governor end of the turbine and an auxiliary oil
pump is often used for oil lift systems to ensure bearing
lubrication is assured during startup or coast down.
• Standard shell and tube heat exchangers are used as oil coolers and
typical oil temperatures are 140ºF (60ºC) entering the cooler and
120ºF (49ºC) exiting the cooler.
• Where a generator, compressor or other device is driven by the
turbine, the central lubrication system usually lubricates the bearings
and auxiliary components of the driven
• machinery.
• Since about 1980, stainless steel oil reservoirs and piping have
become the industry standard and where required, oil heaters have
been available mounted in the reservoirs.
• Full flow oil filters are used and are rated in the 5 to 10 micron
absolute ranges.
• On some systems, a “side stream” or “kidney” filter is installed as a
return line filter to the reservoir to maintain the oil in extremely clean
condition and to remove water which may have entered past steam
seals in systems with high back pressure, or high first stage pressure.
• The lubricant used in steam turbines must be a premium quality recirculating oil
• with excellent thermal and oxidation stability, in order to prevent varnish and sludge
• formation at bearing oil temperatures that may occasionally reach 200ºF (94ºC).
• In addition, the lubricant must have high quality rust and corrosion prevention
• characteristics and must readily shed the water that may enter steam turbine systems.
• Lubricants used in these systems are either mineral oil or polyalphaolefin synthetic base
• in ISO viscosity grades of 32, 46, or 68. Lubricants containing these qualities have
• served in many well maintained steam turbine systems for thirty (30) years without
• change out.
• In many smaller, medium speed steam turbines, bearing lubrication is provided by
• a ring oiling design, where a ring rotates over the journal, or through a slot in the journal
• bearing. The ring picks up oil as it rotates and distributes the oil to the bearing and shaft.
• Oil rings rotate with the
journal to pick up and
provide lubricant.
• The inspection plug in
the cap shown by the
arrow can be removed to
• inspect oil level which is
critical. Too little oil
results in inadequate
• lubrication. Too high oil
level allows the ring to
drag causing flat
• spots on the ring
reducing the ring’s action
also reducing lubrication
• All steam turbines are equipped with two independent governors,
the first to shut
• off steam supply in emergencies and a second to maintain speed.
Speed control governor
• systems include centrifugal mechanical, hydraulic pilot valve and
electronic (or
• electrical) speed sensitive devices.
• Electrohydraulic speed control governors are particularly susceptible
to contaminated oil
• and the lubricants in these systems must be kept contamination free
to protect the servo
• valves.
• Radial journal bearings are of the split shell, three lobe,
or tilting pad anti-whip type, depending upon turbine
design, speed or application.
On the left is the three lobe bearing, which tends to keep the shaft
centralized by the hydrodynamic oil film, while the tilting pad bearing
on the right provides for multiple oil films to ensure stability of the
journal.
• The wide groove in the upper half of this split shell ends
with a
• machined oil dam. As the insert shows, the dam provides a
• downward pressure to stabilize the journal and prevent oil
whirl or
• whip.
• 1. On-Line Monitoring; should include steam consumption, inlet, intermediate
and
• final steam pressure and temperature measurements. Turbine stage pressures
• should be monitored in order to obtain information as to blade condition, such
as
• deformation, damage, or deposit formation.
• Bearing oil pressure and temperature monitoring is recommended. A reduction
in
• pressure may indicate increased bearing clearance, while an increase in
• temperature might indicate a change in bearing geometry or condition. These
• practices should be done in conjunction with an on-going oil and vibration
• analysis program.
• 2. Scheduled Maintenance and Inspection Activities should include periodic
• inspections for oil leaks in piping, at bearing seals, or hydraulic lines. Inspect
• joints and valve mechanism for steam leaks. Inspect governor and throttle valves
• and/or linkage to ensure proper operation. Inspect and operate emergency or
• auxiliary oil pumps to ensure they start when main oil pump pressure drops.
• Inspect the governor to ensure that it holds the speed in all conditions. Inspect the
• overspeed trip valve for proper operation. Inspect turbine rotor sealing glands for
• leakage. Measure and maintain alignment, inspect base plate, grouting, piping
• and piping anchors for damage or looseness.
• If changes in turbine stage pressures have occurred, carry out a borescope
• inspection if the turbine manufacturer has provided borescope access points. If no
• access points have been provided by the manufacturer, it is sometimes possible to
• remove accessories or covers, which will allow at least partial borescope
• inspection and where modifications for access are possible, these maintainability
• improvements should be carried out.
• If changes in thrust or journal bearing temperature or oil pressure indicate
• possible problems, bearing radial and thrust clearance should be determined.
• Above all, establish and maintain accurate and detailed maintenance records that
• include reports, drawings, specifications, photos and all related information
• associated with operational changes, process improvements, repairs,
• modifications and failure analysis documentation.
